Bi-directional multi-port applications

ABSTRACT

Methods and systems for bi-directional multi-port power conversion systems and applications are disclosed. In some sample embodiments, current-modulating power converters can be used to provide conversion between synchronous and asynchronous power. In some sample embodiments, current-modulating power converters can perform power conversion can be performed to and from three-phase AC with an active neutral line. In some sample embodiments, current-modulating power converters can convert between synchronous and asynchronous power and also support three-phase AC with active neutral.

CROSS-REFERENCE

Priority is claimed from U.S. Provisional 61/778,648 filed Mar. 13,2013, which is hereby incorporated by reference.

BACKGROUND

The present application relates to power converters, and moreparticularly to bidirectional power converters.

Note that the points discussed below may reflect the hindsight gainedfrom the disclosed inventions, and are not necessarily admitted to beprior art.

A new kind of power converter was disclosed in U.S. Pat. No. 7,599,196entitled “Universal power conversion methods,” which is incorporated byreference into the present application in its entirety. This patentdescribes a bidirectional (or multidirectional) power converter whichpumps power into and out of a link inductor which is shunted by acapacitor.

The switch arrays at the ports are operated to achieve zero-voltageswitching by totally isolating the link inductor+capacitor combinationat times when its voltage is desired to be changed. (When theinductor+capacitor combination is isolated at such times, the inductor'scurrent will change the voltage of the capacitor, as in a resonantcircuit. This can even change the sign of the voltage, without loss ofenergy.) This architecture has subsequently been referred to as a“current-modulating” or “Power Packet Switching” architecture.Bidirectional power switches are used to provide a full bipolar(reversible) connection from each of multiple lines, at each port, tothe rails connected to the link inductor and its capacitor. The basicoperation of this architecture is shown, in the context of thethree-phase to three-phase example of patent FIG. 1, in the sequence ofdrawings from patent FIG. 12a to patent FIG. 12j.

The ports of this converter can be AC or DC, and will normally bebidirectional (at least for AC ports). Individual lines of each port areeach connected to a “phase leg,” i.e. a pair of switches which permitthat line to be connected to either of two “rails” (i.e. the twoconductors which are connected to the two ends of the link inductor). Itis important to note that these switches are bidirectional, so thatthere are four current flows possible in each phase leg: the line cansource current to either rail, or can sink current from either rail.

Many different improvements and variations are shown in the basicpatent. For example, variable-frequency drive is shown (for controllinga three-phase motor from a three-phase power line), DC and single-phaseports are shown (patent FIG. 21), as well as three- and four-portsystems, applications to photovoltaic systems (patent FIG. 23),applications to Hybrid Electric vehicles (patent FIG. 24), applicationsto power conditioning (patent FIG. 29), half-bridge configurations(patent FIGS. 25 and 26), systems where a transformer is included (tosegment the rails, and allow different operating voltages at differentports) (patent FIG. 22), and power combining (patent FIG. 28).

Improvements and modifications of this basic architecture have also beendisclosed in U.S. Pat. Nos. 8,391,033, 8,295,069, 8,531,858, and8,461,718, all of which are hereby incorporated by reference.

The term “converter” has sometimes been used to refer specifically toDC-to-DC converters, as distinct from DC-AC “inverters” and/or AC-ACfrequency-changing “cycloconverters.” However, in the presentapplication the word converter is used more generally, to refer to allof these types and more, and especially to converters using acurrent-modulating or power-packet-switching architecture.

Electrical power is often supplied in formats which can be initiallyincompatible with formats required by one or more loads. Conversion canbe required between, for example, direct current (DC) and alternatingcurrent (AC), DC and DC, and AC and AC, in order to transfer powerbetween various loads and supplies in a system.

A power converter can thus be necessary to perform any or all of theseinter-conversions. Conventional power converters usually include aninverter which performs the conversion. Conventional inverters, in turn,typically include a transformer as an integral component for the actualcurrent conversion. However, transformers are typically large and heavy,increasing installation costs and space requirements.

Within the realm of conventional power converters, bi-directionalmulti-port power converters can be highly desirable. In, for example, anelectrical power grid, when production exceeds consumption, the excessenergy can be stored in batteries for later use. If, for example,consumption then later exceeds production, energy stored in thebatteries can then be used to power some or all consumption demands onthe power grid.

However, differences between input power and requirements of a givenload can result in multi-stage conversion. Each additional conversionstage can introduce more losses, decreasing efficiency and increasingcosts.

SUMMARY

The present inventors have realized that an energy transfer reactance,which can be e.g. an inductor and capacitor in parallel, can be used ina bi-directional multi-port power converter. In this way, efficientconversion can be performed between, e.g., DC, single-phase AC,three-phase AC, synchronous AC, asynchronous AC, and others.Asynchronous-synchronous conversion in particular can be implemented incombination with an active neutral line to provide surprising synergieswith such power converters.

The disclosed innovations, in various embodiments, provide one or moreof at least the following advantages. However, not all of theseadvantages result from every one of the innovations disclosed, and thislist of advantages does not limit the various claimed inventions.

-   -   Increased efficiency    -   Decreased size    -   Reduced cost

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosed inventions will be described with reference to theaccompanying drawings, which show important sample embodiments and whichare incorporated in the specification hereof by reference, wherein:

FIG. 1 shows a first bi-directional multi-port power conversion system,according to an embodiment.

FIG. 2 shows a second bi-directional multi-port power conversion system,according to an embodiment.

FIG. 3A shows a simplified schematic of a sample power converter.

FIG. 3B shows sample voltage and current waveforms for a power cycle ofa sample power converter.

FIG. 3C shows an exemplary finite state machine for one sample controlarchitecture.

FIGS. 3D, 3E, and 3F show sample embodiments of output and inputvoltages.

FIG. 3G shows one sample embodiment of a bidirectional switch.

FIG. 3H shows one sample embodiment of a bidirectionalcurrent-modulating power converter.

FIGS. 3I, 3J, 3K, 3L, 3M, 3N, 3O, 3P, 3Q, and 3R show sample voltage andcurrent waveforms on an inductor during a typical cycle whiletransferring power at full load from input to output.

FIG. 3S shows voltage and current waveforms corresponding to the fullpower condition of FIGS. 3I-3R, with the conduction mode numberscorresponding to the mode numbers of FIGS. 3I-3R.

FIG. 3T shows an embodiment of the present inventions with a full bridgethree phase cycle topology, with controls and I/O filtering, including athree phase input line reactor as needed to isolate the small but highfrequency voltage ripple on the input filter capacitors from theutility.

FIG. 3U shows an embodiment of the present inventions with DC or SinglePhase portals.

FIG. 3V shows an embodiment of the present inventions with atransformer/inductor.

FIG. 3W shows an embodiment of the present inventions in a four portalapplication mixing single phase AC and multiple DC portals, as can beused to advantage in a solar power application.

FIG. 3X shows an embodiment of the present inventions in a three portalapplication mixing three phase AC portals and a DC portal, as can beused to advantage in a Hybrid Electric Vehicle application.

FIG. 3Y shows an embodiment of the present inventions as a Half-BridgeBuck-Boost Converter in a Single Phase AC or DC Topology with BCBS.

FIG. 3Z show a sample embodiment in a Half-Bridge Buck-Boost Converterin a Three Phase AC Topology with BCBS.

FIG. 3AA shows a sample embodiment in a single phase to three phasesynchronous motor drive.

FIG. 3BB shows a sample embodiment with dual, parallel, “power modules”,each of which consists of 12 bi-directional switches and a parallelinductor/capacitor. More than two power modules can of course be usedfor additional options in multiway conversion.

FIG. 3CC shows an embodiment of the present inventions as a three phasePower Line Conditioner, in which role it can act as an Active Filterand/or supply or absorb reactive power to control the power factor onthe utility lines.

FIG. 3DD shows a sample schematic of a microgrid embodiment.

FIG. 3EE shows another sample embodiment of a microgrid.

FIG. 4 shows a third bi-directional multi-port power conversion system,according to an embodiment.

FIG. 5 shows a schematic view for an electric vehicle application,according to an embodiment

FIG. 6 shows a schematic view for a power generator application,according to an embodiment.

FIG. 7 shows a schematic view for a power generator with micro-gridapplication, according to an embodiment.

FIG. 8 shows a schematic view for an asynchronous power generationapplication, according to an embodiment.

DETAILED DESCRIPTION OF SAMPLE EMBODIMENTS

The numerous innovative teachings of the present application will bedescribed with particular reference to presently preferred embodiments(by way of example, and not of limitation). The present applicationdescribes several inventions, and none of the statements below should betaken as limiting the claims generally.

Some exemplary parameters will be given to illustrate the relationsbetween these and other parameters. However it will be understood by aperson of ordinary skill in the art that these values are merelyillustrative, and will be modified by scaling of further devicegenerations, and will be further modified to adapt to differentmaterials or architectures if used.

Definitions:

Anchoring—Using a switch to fix the voltage of one end of the link of aline voltage. Any change in link voltage will occur on the other end ofthe link.

Direct Anchoring—Leaving one switch of line pair closed after a chargetransfer is complete to anchor the voltage of one end of the link to theline voltage.

Indirect Anchoring—Anchoring that occurs at the start of a chargetransfer one the change in link voltage cause one switch to conduct andanchor that end of the link to the line voltage.

Dominant Phase—The phase of the three phase port that has the largestamount of charge to be transfer to the link.

FPGA—Field programmable gate array.

GFDI—Ground fault detection and interruption.

Islanding—When part of a power system consisting of one or more powersources and loads that is, for some period of time, is separated fromthe rest of the system.

Link—Inductor and capacitor pair that transfer energy between input andoutput line pairs.

Line pair—Two lines of a port that can transfer energy to or from thelink.

Line pair switches—The bidirectional switches that connect a line pairto the link. The switches are composed of two IGBT in series withparallel diodes.

Microgrid—A small power grid to deliver power from a converter to localloads. The converter is the only power source of the microgrid.

MPPT—Maximum Power Point Tracking, algorithm to maximize the amount ofpower from a photovoltaic array

Referring initially to FIG. 3H, illustrated is a schematic of a samplethree phase converter 100 that illustrates the operation of apower-packet-switching converter. The converter 100 is connected to afirst and second power ports 122 and 123 each of which can source orsink power, and each with a line for each phase of the port. Converter100 can transfer electric power between said ports while accommodating awide range of voltages, current levels, power factors, and frequenciesbetween the ports.

The first port can be for example, a 460 VAC three phase utilityconnection, while said second port can be a three phase induction motorwhich is to be operated at variable frequency and voltage so as toachieve variable speed operation of said motor. The present inventionscan also accommodate additional ports on the same inductor, as can bedesired to accommodate power transfer to and from other power sourcesand/or sinks, as shown in FIGS. 3W and 3X.

Referring to FIG. 3H, converter 100 is comprised of a first set ofelectronic switches S_(1u), S_(2u), S_(3u), S_(4u), S_(5u), and S_(6u)that are connected between a first line 113 of a link inductor 120 andeach phase, 124 through 129, of the input port, and a second set ofelectronic switches S_(1l), S_(2l), S_(3l), S_(4l), S_(5l), and S_(6l)that are similarly connected between a second line 114 of link inductor120 and each phase of the output port. A link capacitor 121 is connectedin parallel with the link inductor, forming the link reactance. Each ofthese switches is capable of conducting current and blocking current inboth directions, as seen in e.g. FIG. 3G. Many other such bi-directionalswitch combinations are also possible.

The converter 100 also has input and output capacitor filters 130 and131, respectively, which smooth the current pulses produced by switchingcurrent into and out of inductor 120. Optionally, a line reactor 132 canbe added to the input to isolate the voltage ripple on input capacitorfilter 131 from the utility and other equipment that can be attached tothe utility lines. Similarly, another line reactor, not shown, can beused on the output if required by the application.

For illustration purposes, assume that power is to be transferred in afull cycle of the inductor/capacitor from the first to the second port,as is illustrated in FIG. 3S. Also assume that, at the instant the powercycle begins, phases A_(i) and B_(i) have the highest line to linevoltage of the first (input) port, link inductor 120 has no current, andlink capacitor 121 is charged to the same voltage as exists betweenphase A_(i) and B_(i). The controller FPGA 1500, shown in FIG. 3T, nowturns on switches S_(1u) and S_(2l), whereupon current begins to flowfrom phases A_(i) and B_(i) into link inductor 120, shown as Mode 1 ofFIG. 3I.

FIG. 3S shows the inductor current and voltage during the power cycle ofFIGS. 3I-3R, with the Conduction Mode sequence 1300 corresponding to theConduction Modes of FIGS. 3I-3R. The voltage on the link reactanceremains almost constant during each mode interval, varying only by thesmall amount the phase voltage changes during that interval. After anappropriate current level has been reached, as determined by controller1500 to achieve the desired level of power transfer and currentdistribution among the input phases, switch S_(2l) is turned off.

Current now circulates, as shown in FIG. 3J, between link inductor 120and link capacitor 121, which is included in the circuit to slow therate of voltage change, which in turn greatly reduces the energydissipated in each switch as it turns off. In very high frequencyembodiments of the present inventions, the capacitor 121 can consistsolely of the parasitic capacitance of the inductor and/or other circuitelements. (Note that a similar process is shown in FIG. 3O.)

To continue with the cycle, as shown as Mode 2 in FIG. 3K and FIG. 3S,switch S_(3l) is next enabled, along with the previously enabled switchS_(1u). As soon as the link reactance voltage drops to just less thanthe voltage across phases A_(i) and C_(i), which are assumed for thisexample to be at a lower line-to-line voltage than phases A_(i) andB_(i), switches S_(1u) and S_(3l) become forward biased and start tofurther increase the current flow into the link inductor, and thecurrent into link capacitor temporarily stops.

The two “on” switches, S_(1u) and S_(3l), are turned off when thedesired peak link inductor current is reached, said peak link inductorcurrent determining the maximum energy per cycle that can be transferredto the output. The link inductor and link capacitor then again exchangecurrent, as shown if FIG. 3J, with the result that the voltage on thelink reactance changes sign, as shown in graph 1301, between modes 2 and3 of FIG. 3S. Now as shown in FIG. 3L, output switches S_(5u) and S_(6l)are enabled, and start conducting inductor current into the motor phasesA_(o) and B_(o), which are assumed in this example to have the lowestline-to-line voltages at the present instance on the motor.

After a portion of the inductor's energy has been transferred to theload, as determined by the controller, switch S_(5u) is turned off, andS_(4u) is enabled, causing current to flow again into the linkcapacitor. This increases the link inductor voltage until it becomesslightly greater than the line-to-line voltage of phases A_(o) andC_(o), which are assumed in this example to have the highestline-to-line voltages on the motor. As shown in FIG. 3M, most of theremaining link inductor energy is then transferred to this phase pair(into the motor), bringing the link inductor current down to a lowlevel.

Switches S_(4u) and S_(6l) are then turned off, causing the linkinductor current again to be shunted into the link capacitor, raisingthe link reactance voltage to the slightly higher input line-to-linevoltage on phases A_(i) and B_(i). Any excess link inductor energy isreturned to the input. The link inductor current then reverses, and theabove described link reactance current/voltage half-cycle repeats, butwith switches that are compeimentary to the first half-cycle, as isshown in FIGS. 3N-3R, and in Conduction Mode sequence 1300, and graphs1301 and 1302. FIG. 3O shows the link reactance current exchange duringthe inductor's negative current half-cycle, between conduction modes.

Note that TWO power cycles occur during each link reactance cycle: withreference to FIGS. 3I-3R, power is pumped IN during modes 1 and 2,extracted OUT during modes 3 and 4, IN again during modes 5 and 6(corresponding to e.g. FIG. 3P), and OUT again during modes 7 (as ine.g. FIG. 3Q) and 8. The use of multi-leg drive produces eight modesrather than four, but even if polyphase input and/or output is not used,the presence of TWO successive in and out cycles during one cycle of theinductor current is notable.

As shown in FIGS. 3I-3S, Conduction Mode sequence 1300, and in graphs1301 and 1302, the link reactance continues to alternate between beingconnected to appropriate phase pairs and not connected at all, withcurrent and power transfer occurring while connected, and voltageramping between phases while disconnected (as occurs between the closelyspaced dashed vertical lines of which 1303 in FIG. 3S is one example.

In general, when the controller 1500 deems it necessary, each switch isenabled, as is known in the art, by raising the voltage of the gate 204on switch 200 above the corresponding terminal 205, as an example.Furthermore, each switch is enabled (in a preferred two gate version ofthe switch) while the portion of the switch that is being enabled iszero or reverse biased, such that the switch does not start conductionuntil the changing link reactance voltage causes the switch to becomeforward biased. Single gate AC switches can be used, as with a one-wayswitch embedded in a four diode bridge rectifier, but achievingzero-voltage turn on is difficult, and conduction losses are higher.

In FIG. 3T, current through the inductor is sensed by sensor 1510, andthe FPGA 1500 integrates current flows to determine the current flowingin each phase (line) of the input and output ports. Phase voltagesensing circuits 1511 and 1512 allow the FPGA 1500 to control whichswitches to enable next, and when.

FIGS. 3I-3R shows current being drawn and delivered to both pairs ofinput and output phases, resulting in 4 modes for each direction of linkinductor current during a power cycle, for a total of 8 conduction modessince there are two power cycles per link reactance cycle in thepreferred embodiment. This distinction is not dependent on the topology,as a three phase converter can be operated in either 2 modes or 4conduction modes per power cycle, but the preferred method of operationis with 4 conduction modes per power cycle, as that minimizes input andoutput harmonics.

For single phase AC or DC, it is preferred to have only two conductionmodes per power cycle, or four modes per link reactance cycle, as thereis only one input and output pair in that case. For mixed situations, asin the embodiment of FIG. 3X which converts between DC or single phaseAC and three phase AC, there can be 1 conduction mode for the DCinterface, and 2 for the three phase AC, for 3 conduction modes perpower cycle, or 6 modes per link reactance cycle. In any case, however,the two conduction modes per power half-cycle for three phase operationtogether give a similar power transfer effect as the singe conductionmode for single phase AC or DC.

Another sample embodiment of the present inventions is shown in FIG. 3U,which shows a single phase AC or DC to single phase AC or DC converter.Either or both input and output can be AC or DC, with no restrictions onthe relative voltages. If a port is DC and can only have power floweither into or out of said port, the switches applied to said port canbe uni-directional. An example of this is shown with the photovoltaicarray of FIG. 3W, which can only source power.

FIG. 3V shows a sample implementation of a Flyback Converter. Thecircuit of FIG. 3U has been modified, in that the link inductor isreplaced with a transformer 2200 that has a magnetizing inductance thatfunctions as the link inductor. Any embodiment of the present inventionscan use such a transformer, which can be useful to provide fullelectrical isolation between ports, and/or to provide voltage andcurrent translation between ports, as is advantageous, for example, whena first port is a low voltage DC battery bank, and a second port is 120volts AC, or when the converter is used as an active transformer.

In the embodiments of the present inventions shown in FIGS. 3W and 3X,the number of ports attached to the link reactance is more than two,simply by using more switches to connect in additional ports to theinductor. As applied in the solar power system of FIG. 3W, this allows asingle converter to direct power flow as needed between the ports,regardless of their polarity or magnitude.

Thus, in one sample embodiment, the solar photovoltaic array can be atfull power, e.g. 400 volts output, and delivering 50% of its power tothe battery bank at e.g. 320 volts, and 50% to the house AC at e.g. 230VAC. Prior art requires at least two converters to handle thissituation, such as a DC-DC converter to transfer power from the solar PVarray to the batteries, and a separate DC-AC converter (inverter) totransfer power from the battery bank to the house, with consequentialhigher cost and electrical losses. The switches shown attached to thephotovoltaic power source need be only one-way since the source is DCand power can only flow out of the source, not in and out as with thebattery.

In the sample power converter of FIG. 3X, as can be used for a hybridelectric vehicle, a first port is the vehicle's battery bank, a secondport is a variable voltage, variable speed generator run by thevehicle's engine, and a third port is a motor for driving the wheels ofthe vehicle. A fourth port, not shown, can be external single phase 230VAC to charge the battery. Using this single converter, power can beexchanged in any direction among the various ports. For example, themotor/generator can be at full output power, with 50% of its power goingto the battery, and 50% going to the wheel motor. Then the driver candepress the accelerator, at which time all of the generator power can beinstantly applied to the wheel motor. Conversely, if the vehicle isbraking, the full wheel motor power can be injected into the batterybank, with all of these modes using a single converter.

FIGS. 3Y and 3Z show half-bridge converter embodiments of the presentinventions for single phase/DC and three phase AC applications,respectively. The half-bridge embodiment requires only 50% as manyswitches, but results in 50% of the power transfer capability, and givesa ripple current in the input and output filters which is about doublethat of the full bridge implementation for a given power level.

FIG. 3AA shows a sample embodiment as a single phase to three phasesynchronous motor drive, as can be used for driving a householdair-conditioner compressor at variable speed, with unity power factorand low harmonics input. Delivered power is pulsating at twice the inputpower frequency.

FIG. 3BB shows a sample embodiment with dual, parallel power modules,with each module constructed as per the converter of FIG. 3H, excludingthe I/O filtering. This arrangement can be advantageously used wheneverthe converter drive requirements exceed that obtainable from a singepower module and/or when redundancy is desired for reliability reasonsand/or to reduce I/O filter size, so as to reduce costs, losses, and toincrease available bandwidth.

The power modules are best operated in a manner similar to multi-phaseDC power supplies such that the link reactance frequencies are identicaland the current pulses drawn and supplied to the input/output filtersfrom each module are uniformly spaced in time. This provides for a moreuniform current draw and supply, which can greatly reduce the per unitfiltering requirement for the converter. For example, going from one totwo power modules, operated with a phase difference of 90 degreesreferenced to each of the modules inductor/capacitor, produces a similarRMS current in the I/O filter capacitors, while doubling the ripplefrequency on those capacitors. This allows the same I/O filtercapacitors to be used, but for twice the total power, so the per unitI/O filter capacitance is reduced by a factor of 2. More importantly,since the ripple voltage is reduced by a factor of 2, and the frequencydoubled, the input line reactance requirement is reduced by 4, allowingthe total line reactor mass to drop by 2, thereby reducing per unit linereactance requirement by a factor of 4.

FIG. 3CC shows a sample embodiment as a three phase Power LineConditioner, in which role it can act as an Active Filter and/or supplyor absorb reactive power to control the power factor on the utilitylines. If a battery, with series inductor to smooth current flow, isplaced in parallel with the output capacitor 2901, the converter canthen operate as an Uninterruptible Power Supply (UPS).

FIG. 3A shows an example of a circuit implementing this architecture. Inthis example, one port is used for connection to the AC grid (or otherthree-phase power connection). The other is connected to a motor, toprovide a variable-frequency drive.

In FIG. 3A, an LC link reactance is connected to two DC ports having twolines each, and to a three-phase AC port. Each line connects to a pairof bidirectional switches, such that one bidirectional switch connectsthe respective line to a rail at one side of the link reactance and theother bidirectional switch connects the line to a rail at the other sideof the link reactance.

In one sample embodiment, voltage and current across a link reactancecan be seen in, e.g., FIG. 3B. Link voltage waveform 1301 and linkcurrent waveform 1302 correspond to an arbitrary set of inputs andoutputs. After a conduction interval begins and the relevant switchesare activated, voltage 1301 on the link reactance remains almostconstant during each mode interval, e.g. during each of modes 1-8. Afteran appropriate current level has been reached for the present conductionmode, as determined by the controller, the appropriate switches areturned off. This can correspond to, e.g., conduction gap 1303. Theappropriate current level can be, e.g., one that can achieve the desiredlevel of power transfer and current distribution among the input phases.

Current can now circulate between the link inductor and the linkcapacitor, which is included in the circuit to slow the rate of voltagechange. This in turn greatly reduces the energy dissipated in eachswitch as it turns off After the link voltage reaches appropriate levelsfor the next set of lines, the appropriate switches are enabled, andenergy transfer between the port and the link continues with the nextline pair.

A power converter according to some embodiments of this architecture canbe controlled by, e.g., a Modbus serial interface, which can read andwrite to a set of registers in a field programmable gate array (FPGA).These registers can define, e.g., whether a port is presently an input,an output, or disabled. Power levels and operation modes can also bedetermined by these registers.

In some embodiments, a DC port preferably has one line pair, where eachline pair is e.g. a pair of lines that can transfer energy to or fromthe link reactance through semiconductor switches. A three-phase AC portwill always have three lines, and will often have a fourth (neutral),but only two are preferably used for any given power cycle (of theinductor).

Given three lines, there are three possible two-line combinations. Forexample, given lines A, B, and C, the line pairs will be A-B, B-C, andA-C.

Register values for each port can be used to determine the amount ofcharge, and then the amount of energy, to be transferred to or from eachport during each conduction period. An interface then controls eachport's switches appropriately to transfer the required charge betweenthe link and the enabled ports.

A separate set of working registers can be used in some embodiments tocontrol converter operations. Any value requiring a ramped rate ofchange can apply the rate of change to the working registers.

The mode set for a port during a given power cycle can determine whatfactor will drive the port's power level. This can be, for example,power, current, conductance, or net power. In “net power” mode, theport's power level can be set by, e.g., the sum of other port's powersettings. The mode of at least one port will most preferably be set tonet power in order to source or sink the power set by the other ports.If two ports are set as net power, the two ports will share theavailable power.

A main control state machine and its associated processes can controlthe transfer of power and charge between ports, as seen in FIG. 3C. Thestate machine can be controlled in turn by the contents of registers.The state machine transfers the amount of energy set by the interfacefrom designated input ports to the link reactance, and then transfersthe appropriate amount of energy from the link to designated outputports.

The Reset/Initialize state occurs upon a power reset, when converterfirmware will perform self-tests to verify that the converter isfunctioning correctly and then prepare to start the converter. If nofaults are found, the state machine proceeds to the Wait_Restart state.

The Wait_Restart state can be used to delay the start of the converterupon power up or the restart of the converter when certain faults occur.If a fault occurs, a bleed resistor is preferably engaged. Certainfaults, once cleared, will preferably have a delay before restartingnormal converter operation. The next state will be Startup.

When the Startup state begins, there is no energy in the link. Thisstate will put enough energy into the link to resonate the link to theoperational voltage levels, which are preferably greater than thehighest voltage of any input line pair.

When starting from an AC port, the firmware will wait until a zerovoltage crossing occurs on a line pair of the AC port. The firmware willthen wait until the voltage increases to about 40 volts, then turn onthe switches of the line pair for a short duration. This will put energyinto the link and start the link resonating. The peak resonant voltagemust be greater than the AC line pair for the next cycle. After thefirst energy transfer, more small energy transfers can be made to thelink as the link voltage passes through the line pair voltage,increasing the link's resonant voltage until the link's peak voltage isequal to or greater than the first input line pair voltage. At thispoint, a normal power cycle is ready to start and the state will changeto Power Cycle Start upon detection of a zero current crossing in thelink.

In the Power Cycle Start state, the amount of charge and energy thatwill be transferred to or from the link and each port is determined atthe start of a power cycle. This state begins on a link zero currentcrossing detection, so the link current will be zero at the start of thestate. The link voltage will preferably be equal or greater than thehighest input voltage.

The input and output line pairs that are not disabled is preferablysorted by their differential voltages from the highest voltage to thelowest voltage, where outputs are defined as having a negative voltagewith respect to the start of the current power cycle. If the powerfactor of the AC port is not unity, one of the two line pairs of the ACport will switch between input and output for a portion of a 60 Hzwaveform.

If a DC port's mode is set to have constant current or constant power,the constant current or power levels are converted to equivalentconductance values and used to adjust the relevant port's settingsappropriately. If the port's mode is set to net power, the port willtransfer the sum of all the energy of all other ports not in net powermode.

MPPT (Maximum Power Point Tracking) mode preferably constantly adjuststhe charge put into the Link from a photovoltaic array to maximizetransferred energy. There will typically be a maximum current draw afterwhich voltage begins to decrease, where the particular maximal currentdepends on the photovoltaic array's output characteristics. This maximalcurrent corresponds to maximum power, beyond which point energy transferwill decline. To determine this maximal point, energy transfer can bemonitored while conductance is adjusted until a local maximum is found.There can be some variations in the amount of energy delivered, but thiswill tend to maximize energy transfer.

The charge Q to be transferred to the link can be found as, e.g., theproduct of conductance G, voltage V, and link power cycle period T (i.e.Q=G*V*T). The energy E to be transferred is then simply the product ofthe voltage times the charge (E=V*Q=G*V²*T).

Since other port operation modes prescribe the energy to be transferredto or from the link, at least one port is most preferably in “net power”mode. This assures that at least one port is most preferably thusdependent on the energy in the link, rather than prescribing the same,so that the amount of energy put into the link equals the amount ofenergy taken out of the link.

The amount of energy that is put into the link by other modes is summedtogether to determine the energy transfer to or from ports operating innet power mode. A small amount of energy can in some cases be subtractedfrom this sum if extra energy is to be added to the link this cycle. Ifmultiple ports are operating in net power mode, the available energy ispreferably split between the two ports according to, e.g., the Modbusregisters. The amount of charge to be transferred is preferablydetermined by the relationship charge=energy/voltage.

For an AC port, the phase angle between the voltage and current on theAC port can be varied, based on e.g. power factor settings. An AC portcan also source reactive current for AC port filter capacitors toprevent the filter capacitors from causing a phase shift.

Three-phase charge calculations for a three-phase AC port can, in someembodiments, proceed as follows. Zero crossing of the AC voltagewaveform for a first phase is detected when the voltage changes from anegative to positive. This can be defined as zero degrees, and a phaseangle timer is reset by this zero crossing. The phase angle timer ispreferably scaled by the measured period of the AC voltage to derive theinstantaneous phase angle between the voltage of this first phase andthe zero crossing. The instantaneous phase angle can then be used toread the appropriate sinusoidal scalar from a sinusoidal table for thefirst phase. The instantaneous phase angle can then be adjustedappropriately to determine the sinusoidal scalars for the second andthird phases.

The instantaneous phase angle of the first phase can be decremented bye.g. 90° to read a reactive sinusoidal scalar for the first phase, andthen adjusted again to determine reactive sinusoidal scalars for theother two phases.

The required RMS line current of the port can then be determined, butcan differ dependent on, e.g., whether the port is in net power mode iscontrolled by conductance. In conductance mode, RMS line current can befound by, e.g., multiplying the conductance for the AC port by its RMSvoltage.

In net power mode, RMS line current can be found e.g. as follows. Theenergy transferred to the link by all ports not in net power mode isfirst summed to determine the net power energy available. The smallamount of energy defined by the link energy management algorithm can besubtracted from the available energy if relevant. The net energyavailable is multiplied by the percentage of total power to be allocatedto the present port, which is 100% if only one port is in net powermode: Power=E Energy* port %.

Line RMS current can then be found by dividing the energy for the ACport by the RMS voltage of the port, the link power cycle period, andsquare root of 3: linecurrent_(rms)=Power/(time_(link cycle)*voltage_(rms)*√3).

The instantaneous in-phase current can then be calculated, and willagain differ based on the operational mode of the port. In a conductancemode, the three line-to-line instantaneous voltages can be multiplied bythe port conductance to determine the instantaneous current of eachphase.

In net power mode, the sinusoidal scalar for each phase can bemultiplied by the RMS line current to determine the instantaneouscurrent of each phase. Alternately, voltages from an analog/digitalconverter can be used to find the instantaneous currents directly:Instantaneous Current=energy*V_(a/d)/(3*period*Vrms²). The charge canthen be found as Q=energy*V_(a/d)/(3*Vr_(ms) ²).

RMS line reactive current can then be found e.g. from power factor asfollows:Power Factor=Power/(Power+reactive power)reactive power=(Power/power factor)−Powerreactive power_(line to line)−Power/(3*power factor)−Power/3rms reactive current_(line)=reactive power_(line to line)/rmsvoltage_(line to line).

Filter capacitive current can then be calculated from the filtercapacitance values, line to line voltage, and frequency. Capacitivecompensation current can then be added to the RMS line reactive currentto determine the total RMS line reactive current. Total RMS reactivecurrent can then be multiplied by the reactive sinusoidal scalar toderive the instantaneous reactive current for each phase.

The instantaneous current and the instantaneous current for each phasecan then be added together and multiplied by the period of the linkpower cycle to determine the amount of charge to be transferred for eachphase.

The energy to transfer to or from the link can be found by multiplyingthe charge value of each phase by the instantaneous voltage and summingthe energy of the three phases together.

The phase with the largest charge will be dominant phase for this cycle,and the two line pairs for the AC port will be between the dominantphase and each of the other two phases. The amount of charge to betransferred for each line pair is preferably the amount of chargecalculated for the non-dominant line of the pair. The next state will bethe Charge Transfer state.

In the Charge Transfer state, a first line pair is selected and therespective switches turned on. Even though the switches are on, noconduction will occur until the voltage of the link drops below that ofan input line pair, or rises above the voltage of an output line pairwhere appropriate. If one end of the link inductor reaches the voltageof one line of the line pair, that end of the link inductor isindirectly anchored to the respective line. The link inductor willsubsequently not change in voltage until the respective switch is turnedoff.

The voltage of the line pair is then compared to the integrated linkvoltage. It is generally assumed that current will begin to flow throughthe switches once the integrated link voltage reaches the voltage of theline pair, minus a switch voltage drop. This switch voltage drop isassumed to be on the order of e.g. 8 V for a pair of switches.

The amount of charge flowing into or out of the link is monitored. Thecharge can be found as Q=ΣIΔt, or the sum of the current times the timeinterval.

The link current is typically approximately zero at the start of a powercycle. The link current increases through the end of the last input,then decreases until reaching zero at the beginning of the next powercycle. The link current can be found as I=Σ(V_(instantaneous)Δt/L), orthe sum of the instantaneous voltage times the time interval divided bythe inductance.

When the transferred charge is determined to have met the calculatedamount for the given line pair, the state machine can progress to thenext state. The next state can be Common Mode Management, or can beIdle. If the next state is Idle, all switches are turned off. In somesample embodiments, the state machine will only progress to the CommonMode Management state after the final output line pair.

The Common Mode Management state controls the common mode voltage of thelink, as well as the energy left in the link following the prior state.To control the common mode voltage, one of the switches for the priorline pair is turned off, while the other switch is controlled by theCommon Mode Management state. By having one switch on, the adjacent endof the link can be anchored at the respective line voltage. The voltageat the opposite end of the link can then increase until the currentthrough the inductor drops to zero. The remaining switch can then beturned off. When a zero crossing is detected in the link current, thestate machine will progress to the Idle state.

Two types of anchoring can be used in Common Mode Management. Directanchoring occurs when one switch of a line pair is closed (turned on),which fixes the voltage of the nearest end of the link to the respectiveline voltage. While this switch is turned on, any change to the link'sdifferential voltage will occur on the other end of the link, which willin turn change the link's common mode voltage.

Indirect anchoring occurs when both of a line pair's switches are turnedon prior to a charge transfer. When the voltage of one end of the linkis one switch-voltage-drop below the corresponding line voltage, therespective end of the link is anchored to that voltage. The voltage ofthe other end of the link will continue to change until the voltageacross the link is equal to two switch-voltage-drops below the line pairvoltage. At this point, charge transfer between the link and the linepair begins.

The Common Mode Management state also controls the energy left in thelink after output charge transfer is completed, or after ramp-up. Afterthe last output charge transfer, enough energy will most preferablyremain in the link to have completed the last output charge transfer,and to cause the link voltages first to span, and then to decrease tojust below, the voltages of the first input line pair. This can permitzero-voltage switching of the input switches. Zero-voltage switching, inturn, can reduce switching losses and switch overstressing. The voltagesacross the switches when conduction begins can preferably be e.g. 4 V,but is most preferably no more than 20 V. If insufficient energy remainsin the link to permit zero-voltage switching, a small amount of powercan be transferred from one or more ports in net power mode to the linkduring the subsequent power cycle.

FIG. 3D shows a sample embodiment in which the voltages of the lastoutput span the voltages of the first input. It can be seen that thelink-energy requirements have been met, though small amounts of energycan occasionally be needed to account for link losses.

FIG. 3E shows another sample embodiment in which the voltages of thelast output are spanned by the voltages of the first input. Enoughenergy must be maintained in the link to resonate the link voltages toabove the voltages of the first input. Additional energy can sometimesbe needed to account for small link losses, but the link-energyrequirements can be met fairly easily.

FIG. 3F shows a third sample embodiment, in which the voltages of thelast output neither span nor are spanned by the voltages of the firstinput. Since the last output voltages do not span the first inputvoltages, the link voltage will need to be increased. Enough energy inthe link needs to be maintained in the link to resonate the linkvoltages above the voltages of the first input pair before the linkcurrent crosses zero. This can in some sample embodiments require smallamounts of additional energy to fulfill this requirement.

In each of the sample embodiments of FIGS. 3D-3F, the common modevoltage of the link will preferably be forced toward the common modevoltage of the first input. The switch of the last output furthest involtage from the common mode voltage will preferably be turned offfirst. The link will thus first anchor to the end with a voltage closestto that desired while the other end changes. The other switch ispreferably turned off either once the common mode voltage of the firstinput is turned off or else a zero-crossing is detected in the linkcurrent.

The Idle State most preferably ensures that all link switches remain fora period of time immediately after a switch is turned off. As switchesdo not turn off instantaneously, this can be used to minimizecross-conduction between lines, which can occur when one switch isturned on before another has time to completely turn off. In some sampleembodiments in which the switches comprise e.g. IGBTs, the time betweennominal and actual turn-off of the switches can be significant. Afterthe requisite time has elapsed, the state machine can advance to thenext state. If the prior state was the last line pair, the next state ispreferably the Power Cycle Start state, and is otherwise preferably theCharge Transfer state.

In one sample embodiment, the bidirectional switches can comprise, e.g.,two series IGBTs and two parallel diodes, as in FIG. 3G. In anembodiment like that of FIG. 3G, a bidirectional switch can have twocontrol signals, each controlling one direction of current flow. Otherbidirectional switches are also possible.

Switch control signals are most preferably monitored to preventcombinations of switches being turned which can lead to catastrophicfailures of the converter. Only switches corresponding to a single linepair will preferably be enabled at a time. As relatively few possibleswitch combinations will prevent catastrophic failure, monitoring canlook for the few permissible combinations to allow instead of lookingfor the many combinations to forbid.

Switch control signals can preferably also be monitored to avoid turningnew switches on too quickly after another switch has been turned off.The switches take a finite time to turn off, and turning on anotherswitch too quickly can cause damaging cross-conduction.

Voltage across each switch is also preferably monitored before it isturned on to avoid damaging overvoltage.

Zero-crossings in the link current are preferably detected e.g. using atoroid installed on a link cable. Instead of directly measuring linkcurrent, it can be calculated by integrating the voltage across the linkand scaling the result. This calculated current can preferably be resetevery time a zero-crossing is detected, to prevent long-termaccumulation of error. Zero-crossings, when detected, can also be usedto set the link polarity flag, as the voltage across the link reverseswhen the direction of current flow changes.

In some sample embodiments, power converter voltages can be measuredwith high-speed serial analog-to-digital (A/D) converters. In one sampleembodiment, these converters can have e.g. a 3 MSPS (mega-samples persecond) conversion rate. In one sample embodiment, the converters cantake e.g. 14 clocks to start a conversion and clock in the serial data,leading to e.g. a data latency of 0.3 μs. One sample embodiment can usee.g. 22 such A/D converters.

Islanding occurs when a converter continues to output power when the ACpower grid goes down. This can be extremely dangerous, especially forline crews attempting to fix the AC power grid. Islanding conditions aremost preferably detected and used to trigger a shutdown of theconverter's AC output.

Preferably ground fault detection is used on the DC inputs. When DCcontactors are closed, the voltage drop between the common connection ofa port's connectors and the DC port's ground connection will preferablybe measured. If this voltage is over a certain limit, either too muchground current is present or else the port's ground fuse is blown. Bothof these situations will generate a fault.

A fault will preferably be generated if toroids on input cables detectsurges.

Each DC port will preferably have a pair of contactors connectingpositive and negative power sources to an input ground connection.Configuration information is preferably read from the registers and usedto open or close the contactors as needed. Before contactors are closed,DC filter capacitors are preferably pre-charged to the voltage on theline side of the contactors in order to prevent high-current surgesacross the contacts of the contactors.

An LCD or other type of screen is preferably provided as an interface toa power converter.

The temperature of a heat sink is preferably monitored and used todirect fans. Tachometers on the fans can preferably be monitored, andthe information used to shut down fan control lines if a fan fails. Asthese temperature sensors can occasionally give incorrect information,in some sample embodiments e.g. two preceding readings can be comparedagainst the current temperature reading, and e.g. the median value canbe chosen as the current valid temperature.

In some sample embodiments, a processor can be used to control a powerconverter. This can be e.g. a NIOS processor which is instantiated inthe field-programmable gate array.

In some sample embodiments, an interface to e.g. a 1 GB flash RAM can beused. In one sample embodiment, a flash RAM can have e.g. a 16-bit-widebus and e.g. a 25-bit address bus. In some sample embodiments, an activeserial memory interface can permit reading from, writing to, or erasingdata from a serial configuration flash memory.

In some sample embodiments, a field-programmable gate array can beconnected to e.g. a 1 MB serial nvSRAM with real time clock.

In some sample embodiments, dual row headers on a pc board can be usede.g. for testing and debugging purposes.

In some sample embodiments, LEDs or other indicators can be present on acontrol board. These indicators can be used e.g. for diagnosticpurposes.

To minimize risks of condensation or other types of moisture damagingelectronics, a power converter can preferably be kept in a sealedcompartment. Some air flow is often necessary, however, due to e.g.temperature changes over time. Any air flowing into or out of theconverter most preferably passes through one or more dehumidifiers. Ifleft alone, the dehumidifiers eventually saturate and become useless orworse. Instead, heating elements can preferably be included withdehumidifiers to drive out accumulated moisture. When air flows into theotherwise-sealed compartment, dehumidifiers can remove moisture. Whenair flows out of the compartment, the heating elements can activate, sothat ejected moisture is carried away with the outflowing air instead ofcontinuing into the converter.

FIGS. 3DD and 3EE show two sample embodiments of bi-directionalmulti-port power conversion systems. In this sample embodiment, firstinput port 102 can include a power generator 202 connected to windturbines 204, second input port 104 can include DC port for energystorage, and output port 108 can include an AC power grid.

According to one sample embodiment, generator 202 connected to windturbines 204 can produce asynchronous AC, this asynchronous AC fromgenerator 202 can be transformed to synchronous AC by power conversionmodule 106, and subsequently stored in second input port 104.

Asynchronous

In, for example, an electric vehicle, it can be desirable to route powere.g. from the engine to the battery, from the engine to the motor, fromthe battery to the motor, and from the motor to the battery.

There are many different configurations for power conversion systems,which allow different current conversions such as direct current todirect current (DC to DC), alternating current to alternating current(AC to AC), DC to AC, and DC to AC. Typically, power conversion systemsinclude an inverter, which is a device capable of performing suchconversions. In the state of the art, a typical configuration for aninverter includes a transformer as a main component for currentconversion; however, transformers tend to be large and heavy, increasinginstallation costs and space requirements. Furthermore, advancedinverter designs for single-port and multi-port power conversion systemsinclude capacitors and inductors, in order to filter harmonic periodsand allow desired conductive periods to be transferred to an output.

Bi-directional multi-ports in power conversion systems are convenientfor storing electricity on a large scale within an electrical powergrid. For example, when electricity production exceeds consumption in apower grid, the remaining electrical energy can be stored in batteriesfor later use. On the contrary, when consumption exceeds production, theenergy from these batteries can be used to supply the power demand fromthe grid. Another application for bi-directional power conversionsystems lies on electric vehicles (EV). In general, charging an EV caninclude several power conversion stages, where each stage reducesefficiency and increases costs. A bi-directional multi-port powerconverter can allow decreasing the number of power conversion stages andtherefore, increasing efficiency of the system and decreasing costs.

Bi-directional multi-port power conversion systems are described in thepresent disclosure. In one or more aspects of the present disclosure,bi-directional multi-port power conversion systems can allow to supportmultiple independent DC and AC ports in one single-power conversionstage, therefore increasing power generation efficiency and reducingcosts. In another aspect of the present disclosure, a three-portphotovoltaic and battery converter can eliminate the power electronicsrelated efficiency and cost penalties of integrating photovoltaic andbattery systems. Furthermore, this three-port topology can allow storingenergy generated by a DC port into a battery port, to be thereafter usedin peak demands from a power grid. Similarly, a proposed three-portpower conversion system can allow to optimize power generation of a fuelgenerator in a power grid. This can be achieved by storing generatedelectricity in a battery port when energy production exceeds energyconsumption. Similarly, energy can be retrieved from battery port whenconsumption exceeds production.

According to one sample embodiment, a bi-directional power conversionsystem can be used to transform asynchronous AC to synchronousthree-phase AC with an active neutral.

FIG. 1 shows a first bi-directional multi-port power conversion system100, which can be used to convert energy from first input portal 102 andsecond input portal 104, passing through a power converter 106 to outputportal 108 while adjusting a wide range of voltages, current levels,power factors, and frequencies between portals. According to anembodiment, first input portal 102 can include DC generator, secondinput portal 104 can include a battery port, while output portal 108 canbe a three phase AC port enhanced with an active neutral 110 to supportmicro-grid functionality.

Power converter 106 can include different bi-directional switches 112connected between first input portal 102, second input portal 104, andlink 114 to each input connection, in addition to a second set ofbi-directional switches 112 also connected between output portal 108 andlink 114. Each bi-directional switches 112 is capable of conducting andblocking current in two directions, and can be composed ofbi-directional internal gate bipolar transistors (IGBTs) or otherbidirectional switches. Most combinations of bidirectional switchescontain two independently controlled gates, with each gate controllingcurrent flow in one direction. Generally, in the embodiments described,when switches are enabled, only the gate that controls current in thedesired direction is enabled.

Link 114 can include link inductor 116 and link capacitor 118, connectedin parallel with link inductor 116, forming a resonant circuit that canallow for soft switching and flexibility of adjusting link 114 voltageto meet individual needs of first input portal 102, second input portal104, and output portal 108. Additionally, link 114 can provide isolationbetween first input portal 102, second input portal 104, and outputportal 108, eliminating the need for a transformer, as well as improvingspeed of response and reducing acoustic noise in case of frequency beingoutside audible range.

Furthermore, filter capacitors 120 can be placed between input phasesand also between output phases, in order to closely approximate firstinput portal 102, second input portal 104, and output portal 108, and toattenuate current pulses produced by the bi-directional switches 112 andlink inductor 116. An input line reactor can be needed in someapplications to isolate the voltage ripple on the input and outputfilter capacitors 120.

FIG. 2 shows a second bi-directional multi-port power conversion system200, which can include an input charging 202, rechargeable battery 204,engine motor 206, drive motor 208, and link 114.

Input charging 202 can be a 120/240 V single phase input, which caninclude one or more capacitors 210, one AC voltage source 212, and fourbi-directional switches 112 such as bi-directional internal gate bipolartransistors (IGBTs). AC voltage source 212 can be supplied by a powerdistribution grid. Rechargeable battery 204 can include a Lithium-ionwith a positive and a negative conductive line (not shown in thefigure), one or more capacitors 210, and four bi-directional switches112.

Engine motor 206 can include an internal combustion engine with threephase AC 214, three capacitors 210, and six bi-directional switches 112.Drive motor 208 with regenerative charging, can also include one threephase AC 214, three capacitors 210, and six bi-directional switches 112.

FIG. 4 shows a third bi-directional multi-port power conversion system300, which can include an input charging 202, super-capacitor port 302,rechargeable battery 204, engine motor 206, drive motor 208, and link114. Third bi-directional multi-port power conversion system 300 canfunction with capabilities of high power on-board bi-directional 480VAC>50 kW charger.

Input charging 202 can be a 120/240 V single phase input, which caninclude one or more capacitors 210, one AC voltage source 212, and fourbi-directional switches 112, such as bi-directional internal gatebipolar transistors (IGBTs). AC voltage source 212 can be supplied by apower distribution grid. Super-capacitor port 302 can be used as shortterm storage, which can include one battery source 304, one or morecapacitors 210, and four bi-directional switches 112.

Rechargeable battery 204 can include a Lithium-ion with a positive and anegative conductive line (not shown in the figure), one or morecapacitors 210, and four bi-directional switches 112. Engine motor 206can include an internal combustion engine with three phase AC 214, threecapacitors 210, and six bi-directional switches 112. Drive motor 208with regenerative charging, can also include one three phase AC 214,three capacitors 210, and six bi-directional switches 112.

FIG. 5 shows a schematic view for an electric vehicle application 400,in accordance with first bi-directional multi-port power conversionsystem 100. In this embodiment, first input portal 102 can include athree phase AC, second input portal 104 can include a DC generator suchas a photovoltaic array or a DC storage device such as one or morebatteries, and output portal 108 can include an AC power grid.

According to the present embodiment, second input portal 104 can provideelectric current to an electric vehicle during grid faults from outputportal 108. In a different embodiment, second input portal 104 caninclude a battery port, in order to store energy generated by outputportal 108, subsequently, this energy can be provided to an electricvehicle by first input portal 102.

FIG. 6 shows a schematic view for a power generator application 500, inaccordance with first bi-directional multi-port power conversion system100. In this embodiment, first input portal 102 can include a DCgenerator such as a photovoltaic array, second input portal 104 caninclude a DC storage device such as a battery port, and output portal108 can include an AC power grid.

According to the present embodiment, output portal 108 can be connectedto an AC generator (not shown in the figure). Output portal 108 cansupply energy to a grid or micro-grid (not shown in the figure), whilean AC generator can provide energy to the grid during faults in outputportal 108. When production from this AC generator exceeds consumptionfrom a grid, electric current can be stored in a battery port fromsecond input portal 104, on the contrary, when consumption from a gridexceeds production from AC generator, electric energy can be supplied bysecond input portal 104, in order to level with peak voltage demand,therefore optimizing power generation from the AC generator. Accordingto an embodiment, AC generator can include a fuel based generator.

FIG. 7 shows a schematic view for a power generator with micro-gridapplication 600, in accordance with first bi-directional multi-portpower conversion system 100. Power generator with micro-grid application600 can include first input portal 102, second input portal 104, powerconverter 106, AC panel 602, AC generator 604, critical loads 606, ACdisconnect 608, and output portal 108. In this embodiment, first inputportal 102 can include a DC generator such as a photovoltaic array,second input portal 104 can include a DC storage device such as one ormore batteries, and output portal 108 can include an AC power grid.

According to the present embodiment, AC panel 602 can be connected to anAC generator 604. Additionally, AC panel 602 can be connected to outputportal 108 by AC disconnect 608. During grid faults from output portal108, AC disconnect 608 can be switched to open position, and therefore,AC generator 604, first input portal 102, and second input portal 104can provide power for critical loads 606. Furthermore, AC generator 604can provide additional power to a DC storage device from second inputportal 104, thus, allowing second input portal 104 to reach maximumefficiency. AC generator 604 can include a fuel based generator.

FIG. 8 shows a schematic view for an asynchronous power generationapplication 700, in accordance with first bi-directional multi-portpower conversion system 100. In this embodiment, first input portal 102can include an asynchronous AC port such as a wind turbine, second inputportal 104 can include a DC storage port such as one or more batteries,and output portal 108 can include an AC power grid.

According to the present embodiment, asynchronous AC from first inputportal 102 can be transformed to synchronous AC by power converter 106,and subsequently stored in second input portal 104 by power converter106. Output portal 108 can supply energy to a grid or micro-grid (notshown in the figure) by using energy from second input portal 104, andfirst input portal 102. When production from first input portal 102exceeds consumption from a grid, energy can be stored in a DC port fromsecond input portal 104, on the contrary, when consumption from a gridexceeds production from first input portal 102, energy can be suppliedby second input portal 104, in order to level with peak voltage demand,therefore optimizing power generation from first input portal 102.

According to a different embodiment, a similar topology as the oneexplained in FIG. 7 can be used for asynchronous power generationapplication 700. In this embodiment, first input portal 102 can includean asynchronous AC generator instead of a DC generator.

One sample embodiment is an application for second bi-directionalmulti-port power conversion system 200, where engine motor 206 and drivemotor 208 are subsystems from a plug-in hybrid electric vehicle (PHEV).In this embodiment, second bi-directional multi-port power conversionsystem 200 functions with capabilities of a high power on-boardbi-directional 480 VAC>50 kW charger.

Another sample embodiment is an application for third bi-directionalmulti-port power conversion system 300, where engine motor 206 and drivemotor 208 are subsystems from a plug-in hybrid electric vehicle (PHEV).In this embodiment, third bi-directional multi-port power conversionsystem 300 functions with capabilities of a high power on-boardbi-directional 480 VAC>50 kW charger.

Backup power connections have traditionally presented phasesynchronization requirements, even when frequency synchronization isperfect. If a motor-generator set is started up in isolation, its phase(after it stabilizes at rated frequency) will be random unless it issomehow controlled. Traditionally, synchronized connection can beaccomplished by monitoring the voltage between corresponding phase legsof mains and backup, while slightly shifting phase (or allowingfrequency drift) until near-zero voltage is achieved. (If out-of-phaserotating generators are connected together they will synchronize, with atransient current spike and torque which can both be destructive.)However, this process of physical synchronization is slow—too slow to beacceptable for backup of many mission-critical requirements. If a backupgenerator is kept running “hot,” it can already be pre-synchronized, butthis is very expensive in terms of fuel and maintenance for the hotbackup. Battery backup can be used to provide a “no-break” transition,but this requires sophisticated inverter electronics, and does notitself solve the problem of physical phase synchronization.

The present application teaches that physical phase synchronization isnot required when bringing a backup online, or when connecting a backupto a new grid segment which is not in synch. Instead, the UPC whichmakes an active connection also provides phase shift as needed. Physicalphase synchronization can still be performed in background (andpreferably is), but now phase synchronization can be performed AFTERpower transfer has already started. This provides a more agile(rapid-response) backup capability, even without a “hot” backup.

Thus in one class of implementions, multiple UPCs can combine theirpower outputs onto a single AC power bus. This requires a degree ofsynchronization which is not possible with most other power convertertopologies.

It is well-known that different countries will have differing electricalutility standards. For example, in the United Kingdom, and a number ofrelated countries, the mains supply standard for residentialapplications is 240V at 50 Hz. In the US, the standard is 120V at 60 Hz.Frequently, operating voltage can be set as high as 130V, which is atthe upper edge of the voltage range which has long since been defined.One way to think about these differing standards is that a lower voltagemeans less risk of electrocution from accidental contact with mainswires, but a higher voltage means less risk of accidental fires. Thatis, a high-power consumer appliance such as an air conditioner or a hotwater heater, will draw only half as much current if the supply voltageis doubled, and therefore the ohmic heating which will be caused by anaccidental series resistance, e.g. due to a weakening wire or looseningconnector, will be dropped by 75%. (For a given resistance and a givencurrent, the ohmic power dissipation will vary as I²R.) Moreover,standards which are suitable for residential applications, and even forlight commercial applications, are not adequate for more significantamounts of power.

In the US, in addition to the common standard of 120V single phase, itis also common for higher power appliances, such as residential electricranges or electric dryers, to be operated at 240V single phase. Commonconnector specifications include 30 A and 50 A, but the power availablefrom 50A at 140V is only 12 kW, which is smaller than will be desirablefor many applications. In the US, for example, and in many othercountries, small commercial and light industrial applications commonlyuse 480V three-phase power. By doubling the supply voltage again, the E2component of peak power is quadrupled. Moreover, three-phase power isinherently convenient for driving induction motors, and the additionalconductor provides some additional power capacity for a given currentrating. 240V three-phase power is also common in the US. Moreover, otherpower standards are often used in particular applications. One verycommon example is 30 A ship-to-shore plug, which is used in many boatingand RV applications.

The problem with the diversity of available voltage standards is thatconnectors must be designed not to accidentally interconnectincompatible voltages. An overvoltage applied to an appliance, forexample, can easily lead to fire or shock.

Voltage specification at the outlet is generally determined bytransformer windings. Commonly the cap position on transformers can beadjusted to avoid voltage variation which can be due to cumulativeerrors in other transformers, or can be due to accumulated losses at theend of a long line run. However, this technology does not and cannoteasily permit real-time adjustment of supply voltage. The presentapplication teaches that the new capabilities of the Universal PowerConverter, disclosed in issued U.S. Pat. Nos. 7,599,196, 8,300,426,8,345,452, 7,778,045, 8,391,033, 8,295,069, and others (including US2012/0020129, US 2012/0033464, US 2012/0051100, WO 2012/075172, US2012/0279567, US 2012/0268975, US 2012/0274138, and WO 2012/075189),which are all hereby incorporated by reference, provide new capabilitieswhich can be used to completely change the landscape of electrical powerconnection specifications. Real-time adjustment of voltage (andfrequency and phase and power factor etc.) is now possible.

According to some but not necessarily all embodiments, there isprovided: A bi-directional power converter, comprising: at least twophase legs each connected to a respective line of a first port; eachsaid phase leg comprising two fully bidirectional switching devices, sothat the line connected to that phase leg can either source or sinkcurrent to either terminal of a link inductor which is paralleled by acapacitor; at least four other phase legs each connected to a respectiveline of a second port; each said phase leg comprising two fullybidirectional switching devices, so that the line connected to thatphase leg can either source or sink current to either terminal of saidlink inductor; wherein said lines of said second port provide threepoles and a neutral connection; and, control circuitry which isconnected to drive said switches so that said link inductor is coupledto each said link of said first and second ports at least twice, withopposite polarities, during each full cycle of AC oscillation of saidlink inverter; and wherein said control circuitry is also connected todetect drift of the neutral line of said second port, and configured toapply drive to said neutral line; wherein said control circuitry drivessaid switches so as to synchronize the phase of output current to thephase of an output port.

According to some but not necessarily all embodiments, there isprovided: A bi-directional power converter, comprising: at least twophase legs each connected to a respective line of a first port; eachsaid phase leg comprising four fully bidirectional switching devices, sothat the line connected to that phase leg can either source or sinkcurrent to either terminal of a link inductor which is paralleled by acapacitor; at least two other phase legs each connected to a respectiveline of a second port; each said phase leg comprising six fullybidirectional switching devices, so that the line connected to thatphase leg can either source or sink current to either terminal of saidlink inductor; and, control circuitry which is connected to drive saidswitches so that said link inductor is coupled to each said link of saidfirst and second ports at least twice, with opposite polarities, duringeach full cycle of AC oscillation of said link inverter; wherein saidcontrol circuitry drives said switches so as to synchronize the phase ofoutput current to the phase of an output port.

According to some but not necessarily all embodiments, there isprovided: A bi-directional power converter, comprising: at least twophase legs each connected to a respective line of a first port; eachsaid phase leg comprising six fully bidirectional switching devices, sothat the line connected to that phase leg can either source or sinkcurrent to either terminal of a link inductor which is paralleled by acapacitor; at least two other phase legs each connected to a respectiveline of a second port; each said phase leg comprising six fullybidirectional switching devices, so that the line connected to thatphase leg can either source or sink current to either terminal of saidlink inductor; and, control circuitry which is connected to drive saidswitches so that said link inductor is coupled to each said link of saidfirst and second ports at least twice, with opposite polarities, duringeach full cycle of AC oscillation of said link inverter wherein saidcontrol circuitry drives said switches so as to synchronize the phase ofoutput current to the phase of an output port; wherein said controlcircuitry drives said switches so as to synchronize the phase of outputcurrent to the phase of an output port.

According to some but not necessarily all embodiments, there isprovided: An electric vehicle having a bi-directional multi-port powerconverter, comprising: at least two phase legs each connected to arespective line of a first port; so that the line connected to thatphase leg can either source or sink current to either terminal of a linkinductor which is paralleled by a capacitor; at least two phase legseach connected to a respective line of a second port; so that the lineconnected to that phase leg can either source or sink current to eitherterminal of a link inductor which is paralleled by a capacitor; at leasttwo other phase legs each connected to a respective line of a thirdport; and, control circuitry which is connected to drive said switchesso that said link inductor is coupled to each said link of said firstand second ports at least twice, with opposite polarities, during eachfull cycle of AC oscillation of said link inverter; wherein said controlcircuitry drives said switches so as to synchronize the phase of outputcurrent to the phase of an output port.

According to some but not necessarily all embodiments, there isprovided: A bi-directional multi-port power converter, comprising: atleast two phase legs each connected to a respective line of a firstport; so that the line connected to that phase leg can either source orsink current to either terminal of a link inductor which is paralleledby a capacitor; at least two phase legs each connected to a respectiveline of a second port; so that the line connected to that phase leg caneither source or sink current to either terminal of a link inductorwhich is paralleled by a capacitor; at least two other phase legs eachconnected to a respective line of a third port; so that the lineconnected to that phase leg can either source or sink current to eitherterminal of said link inductor; and, control circuitry which isconnected to drive said switches so that said link inductor is coupledto each said link of said first and second ports at least twice, withopposite polarities, during each full cycle of AC oscillation of saidlink inverter; wherein said control circuitry drives said switches so asto synchronize the phase of output current to the phase of an outputport.

According to some but not necessarily all embodiments, there isprovided: Methods and systems for bi-directional multi-port powerconversion systems and applications are disclosed. In some sampleembodiments, current-modulating power converters can be used to provideconversion between synchronous and asynchronous power. In some sampleembodiments, current-modulating power converters can perform powerconversion can be performed to and from three-phase AC with an activeneutral line. In some sample embodiments, current-modulating powerconverters can convert between synchronous and asynchronous power andalso support three-phase AC with active neutral.

According to some but not necessarily all embodiments, there isprovided: A bi-directional power converter, comprising: at least sixphase legs each connected to a respective line of a first port and asecond port; each said phase leg comprising two fully bidirectionalswitching devices, so that the line connected to that phase leg caneither source or sink current to either terminal of a link inductorwhich is paralleled by a capacitor; wherein each said port has at leastthree lines; control circuitry which is connected to drive said switchesso that said link inductor is coupled to each said line of said firstand second ports at least twice, with opposite polarities, during eachfull cycle of AC oscillation of said link inductor; wherein said controlcircuitry drives said switches so as to synchronize the phase of outputcurrent to the phase of an output port.

According to some but not necessarily all embodiments, there isprovided: A bi-directional power converter, comprising: at least twophase legs each connected to a respective line of a first port; eachsaid phase leg comprising four fully bidirectional switching devices, sothat the line connected to that phase leg can either source or sinkcurrent to either terminal of a link inductor which is paralleled by acapacitor; at least two other phase legs each connected to a respectiveline of a second port; each said phase leg comprising six fullybidirectional switching devices, so that the line connected to thatphase leg can either source or sink current to either terminal of saidlink inductor; and, control circuitry which is connected to drive saidswitches so that said link inductor is coupled to each said link of saidfirst and second ports at least twice, with opposite polarities, duringeach full cycle of AC oscillation of said link inductor; wherein saidcontrol circuitry drives said switches so as to synchronize the phase ofoutput current to the phase of an output port.

According to some but not necessarily all embodiments, there isprovided: A bi-directional power converter, comprising: at least twophase legs each connected to a respective line of a first port; eachsaid phase leg comprising six fully bidirectional switching devices, sothat the line connected to that phase leg can either source or sinkcurrent to either terminal of a link inductor which is paralleled by acapacitor; at least two other phase legs each connected to a respectiveline of a second port; each said phase leg comprising six fullybidirectional switching devices, so that the line connected to thatphase leg can either source or sink current to either terminal of saidlink inductor; and, control circuitry which is connected to drive saidswitches so that said link inductor is coupled to each said link of saidfirst and second ports at least twice, with opposite polarities, duringeach full cycle of AC oscillation of said link inverter; wherein saidcontrol circuitry drives said switches so as to synchronize the phase ofoutput current to the phase of an output port.

According to some but not necessarily all embodiments, there isprovided: An electric vehicle having a bi-directional multi-port powerconverter, comprising: at least two phase legs each connected to arespective line of a first port; so that the line connected to thatphase leg can either source or sink current to either terminal of a linkinductor which is paralleled by a capacitor; at least two phase legseach connected to a respective line of a second port; so that the lineconnected to that phase leg can either source or sink current to eitherterminal of a link inductor which is paralleled by a capacitor; at leasttwo other phase legs each connected to a respective line of a thirdport; and, control circuitry which is connected to drive said switchesso that said link inductor is coupled to each said link of said firstand second ports at least twice, with opposite polarities, during eachfull cycle of AC oscillation of said link inverter; wherein said controlcircuitry drives said switches so as to synchronize the phase of outputcurrent to the phase of an output port.

According to some but not necessarily all embodiments, there isprovided: A bi-directional multi-port power converter, comprising: atleast two phase legs each connected to a respective line of a firstport; so that the line connected to that phase leg can either source orsink current to either terminal of a link inductor which is paralleledby a capacitor; at least two phase legs each connected to a respectiveline of a second port; so that the line connected to that phase leg caneither source or sink current to either terminal of a link inductorwhich is paralleled by a capacitor; at least two other phase legs eachconnected to a respective line of a third port; so that the lineconnected to that phase leg can either source or sink current to eitherterminal of said link inductor; and, control circuitry which isconnected to drive said switches so that said link inductor is coupledto each said link of said first and second ports at least twice, withopposite polarities, during each full cycle of AC oscillation of saidlink inverter; wherein said control circuitry drives said switches so asto synchronize the phase of output current to the phase of an outputport.

According to some but not necessarily all embodiments, there isprovided: A bi-directional power converter, comprising: at least twophase legs each connected to a respective line of a first port; eachsaid phase leg comprising two fully bidirectional switching devices, sothat the line connected to that phase leg can either source or sinkcurrent to either terminal of a link inductor which is paralleled by acapacitor; at least four other phase legs each connected to a respectiveline of a second port; each said phase leg comprising two fullybidirectional switching devices, so that the line connected to thatphase leg can either source or sink current to either terminal of saidlink inductor; wherein said lines of said second port provide threepoles and a neutral connection; and, control circuitry which isconnected to drive said switches so that said link inductor is coupledto each said link of said first and second ports at least twice, withopposite polarities, during each full cycle of AC oscillation of saidlink inverter; and wherein said control circuitry is also connected todetect drift of the neutral line of said second port, and configured toapply drive to said neutral line.

According to some but not necessarily all embodiments, there isprovided: A bi-directional power converter, comprising: at least twophase legs each connected to a respective line of a first port; eachsaid phase leg comprising four fully bidirectional switching devices, sothat the line connected to that phase leg can either source or sinkcurrent to either terminal of a link inductor which is paralleled by acapacitor; at least two other phase legs each connected to a respectiveline of a second port; each said phase leg comprising six fullybidirectional switching devices, so that the line connected to thatphase leg can either source or sink current to either terminal of saidlink inductor; and, control circuitry which is connected to drive saidswitches so that said link inductor is coupled to each said link of saidfirst and second ports at least twice, with opposite polarities, duringeach full cycle of AC oscillation of said link inverter.

According to some but not necessarily all embodiments, there isprovided: A bi-directional power converter, comprising: at least twophase legs each connected to a respective line of a first port; eachsaid phase leg comprising six fully bidirectional switching devices, sothat the line connected to that phase leg can either source or sinkcurrent to either terminal of a link inductor which is paralleled by acapacitor; at least two other phase legs each connected to a respectiveline of a second port; each said phase leg comprising six fullybidirectional switching devices, so that the line connected to thatphase leg can either source or sink current to either terminal of saidlink inductor; and, control circuitry which is connected to drive saidswitches so that said link inductor is coupled to each said link of saidfirst and second ports at least twice, with opposite polarities, duringeach full cycle of AC oscillation of said link inverter.

According to some but not necessarily all embodiments, there isprovided: An electric vehicle having a bi-directional multi-port powerconverter, comprising: at least two phase legs each connected to arespective line of a first port; so that the line connected to thatphase leg can either source or sink current to either terminal of a linkinductor which is paralleled by a capacitor; at least two phase legseach connected to a respective line of a second port; so that the lineconnected to that phase leg can either source or sink current to eitherterminal of a link inductor which is paralleled by a capacitor; at leasttwo other phase legs each connected to a respective line of a thirdport; and, control circuitry which is connected to drive said switchesso that said link inductor is coupled to each said link of said firstand second ports at least twice, with opposite polarities, during eachfull cycle of AC oscillation of said link inverter.

According to some but not necessarily all embodiments, there isprovided: A bi-directional multi-port power converter, comprising: atleast two phase legs each connected to a respective line of a firstport; so that the line connected to that phase leg can either source orsink current to either terminal of a link inductor which is paralleledby a capacitor; at least two phase legs each connected to a respectiveline of a second port; so that the line connected to that phase leg caneither source or sink current to either terminal of a link inductorwhich is paralleled by a capacitor; at least two other phase legs eachconnected to a respective line of a third port; so that the lineconnected to that phase leg can either source or sink current to eitherterminal of said link inductor; and, control circuitry which isconnected to drive said switches so that said link inductor is coupledto each said link of said first and second ports at least twice, withopposite polarities, during each full cycle of AC oscillation of saidlink inverter.

Modifications and Variations

As will be recognized by those skilled in the art, the innovativeconcepts described in the present application can be modified and variedover a tremendous range of applications, and accordingly the scope ofpatented subject matter is not limited by any of the specific exemplaryteachings given. It is intended to embrace all such alternatives,modifications and variations that fall within the spirit and broad scopeof the appended claims.

Additional general background, which helps to show variations andimplementations, may be found in the following publications, all ofwhich are hereby incorporated by reference: U.S. Pat. No. 7,560,906;U.S. RE041965; U.S. Pat. No. 7,378,820; U.S. Pat. No. 6,981,378; U.S.Pat. No. 6,747,370.

Additional general background, which helps to show variations andimplementations, as well as some features which can be implementedsynergistically with the inventions claimed below, may be found in thefollowing US patent applications. All of these applications have atleast some common ownership, copendency, and inventorship with thepresent application, and all of them, as well as any material directlyor indirectly incorporated within them, are hereby incorporated byreference: U.S. Pat. No. 8,406,265, U.S. Pat. No. 8,400,800, U.S. Pat.No. 8,395,910, U.S. Pat. No. 8,391,033, U.S. Pat. No. 8,345,452, U.S.Pat. No. 8,300,426, U.S. Pat. No. 8,295,069, U.S. Pat. No. 7,778,045,U.S. Pat. No. 7,599,196, US 2012-0279567 A1, US 2012-0268975 A1, US2012-0274138 A1, US 2013-0038129 A1, US 2012-0051100 A1; US Provisionals61/765,098, 61/765,099, 61/765,100, 61/765,102, 61/765,104, 61/765,107,61/765,110, 61/765,112, 61/765,114, 61/765,116, 61/765,118, 61/765,119,61/765,122, 61/765,123, 61/765,126, 61/765,129, 61/765,131, 61/765,132,61/765,137, 61/765,139, 61/765,144, 61/765,146 all filed Feb. 15, 2013;61/778,648, 61/778,661, 61/778,680, 61/784,001 all filed Mar. 13, 2013;61/814,993 filed Apr. 23, 2013; 61/817,012, 61/817,019, 61/817,092 filedApr. 29, 2013; 61/838,578 filed Jun. 24, 2013; 61/841,618, 61/841,621,61/841,624 all filed Jul. 1, 2013; 61/914,491 and 61/914,538 filed Dec.11, 2013; 61/924,884 filed Jan. 8, 2014; 61/925,311 filed Jan. 9, 2014;61/928,133 filed Jan. 16, 2014; 61/928,644 filed Jan. 17, 2014;61/929,731 and 61/929,874 filed Jan. 21, 2014; 61/931,785 filed Jan. 27,2014; 61/932,422 filed Jan. 28, 2014; and 61/933,442 filed Jan. 30,2014; and all priority applications of any of the above thereof, eachand every one of which is hereby incorporated by reference.

None of the description in the present application should be read asimplying that any particular element, step, or function is an essentialelement which must be included in the claim scope: THE SCOPE OF PATENTEDSUBJECT MATTER IS DEFINED ONLY BY THE ALLOWED CLAIMS. Moreover, none ofthese claims are intended to invoke paragraph six of 35 USC section 112unless the exact words “means for” are followed by a participle.

The claims as filed are intended to be as comprehensive as possible, andNO subject matter is intentionally relinquished, dedicated, orabandoned.

The invention claimed is:
 1. A bi-directional power converter,comprising: at least two phase legs each connected to a respective phaseline of a first port; each said phase leg comprising two fullybidirectional switching devices, so that the line connected to thatphase leg can either source or sink current to either terminal of a linkinductor which is paralleled by a capacitor; at least two other phaselegs each connected to a respective line of a second port; each saidphase leg comprising two fully bidirectional switching devices, so thatthe line connected to that phase leg can either source or sink currentto either terminal of said link inductor; wherein said lines of saidsecond port provide three phase lines and a neutral line; at least twoother phase legs each connected to a respective phase line of a thirdport; each said phase leg comprising two fully bidirectional switchingdevices, so that the line connected to that phase leg can either sourceor sink current to either terminal of said link inductor; and, controlcircuitry which is connected to drive said switches so that said linkinductor is coupled to each said phase line of said first and secondports at least twice, with opposite polarities, during each full cycleof AC oscillation of said link inverter; and wherein said controlcircuitry is also connected to detect drift of the neutral line of saidsecond port, and configured to apply drive to said neutral line.
 2. Thebi-directional power converter of claim 1, where the respective lines ofthe first port are connected to a super capacitor.
 3. The bi-directionalpower converter of claim 1, where the respective lines of the first portare connected to a rechargeable battery.
 4. The bi-directional powerconverter of claim 1, where the respective lines of the second port areconnected to an engine motor.
 5. The bi-directional power converter ofclaim 1, where the respective lines of the second port are connected toa drive motor.
 6. The bi-directional power converter of claim 1, wherethe respective lines of the third port are connected to a supercapacitor.
 7. The bi-directional power converter of claim 1, where therespective lines of the third port are connected to a rechargeablebattery.